Continuous flow water heater that mitigates the effect of altitude

ABSTRACT

A continuous flow heater that mitigates the effect of altitude, characterized in that it consists of a combustion system with four mixers attached to a rectangular base into which the gas is injected and distributed through fifty small cavities is provided. The combustion system is attached to a heat transfer system. The continuous flow heater that mitigates the effect of altitude is suitable for altitudes greater than 2000 meters above the sea level without notable reductions in power or significant increases in polluting and toxic emissions. The combustion system has better air draft than conventional systems, enabling it to mitigate the reduction in the quantity of oxygen in the air at higher altitudes, improving the operation of the equipment compared to the operation of equipment already available on the market, and making a better use of non-renewable natural resources.

FIELD OF TECHNOLOGY

The following relates to devices for residential destination, specifically to electrical household appliances and gas household appliances. More specifically, it relates to a continuous flow water heater that uses gas for its operation, which its performance is not affected when operated at different altitudes above the sea level.

BACKGROUND

The major technological developments in the area of gas combustion have focused throughout history in first world countries, with the particularity that its geography does not include large urban settlements at altitudes higher than 2,000 meters above the sea level. All global norms on issues of management and use of combustible gases have American and European standards (mostly French) as historical records, but there has not been a general concern about the use of gaseous fuels at high altitudes.

In areas with significant altitude, as are many Andean countries, there has been the problem of mitigating the effect of altitude on water heaters. However, the technologies in the prior art have large manufacturing problems and have application in products that are directed to the final user. Indeed, when thermal equipment operates at a higher altitude over the sea level, there are several negative effects, among which we can list:

-   -   1. Difficulty of ignition.     -   2. Increments of toxic emissions.     -   3. Thermal power decreasing.     -   4. Flame stability problems.

The causes of the drawbacks listed above may be focused on two representative changes that occur with increasing altitude: decreasing the amount of oxygen present in the air and the change in the density of the gases by the change in the atmospheric pressure.

Instead, when an equipment that operates with fuel gases at sea level works, there is a thermal power and toxic emissions that are considered ideal and alt manufacturers worldwide are committed to the operation of the equipment under this operating condition, especially if the rules applicable to household equipment that operates with fuel gases, in all mathematical formalisms, try to extrapolate the operation anywhere in the condition of the sea level.

Continuous flow water heaters do not escape from the difficulties described that are common to all the gas household appliances. These use fuel gas as a heat source, so that products of combustion circulate through a heat exchanger having an external coil in which the water circulates at room temperature from the water network of the house, this water subsequently increases its temperature about 25° C. (depending on the flow and installation conditions) and will be used on showers, laundry and cooking appliances.

American standards include the use of combustible gases at altitudes higher than 1000 meters above the sea level, performing an operation known as American derating; this practice seeks to reduce the thermal power of the products at a value about 4% for every 304 meters above the sea level where the equipment is operating, a situation which is in contrast to the requirement of use, because at higher altitudes to the sea, there are lower temperatures and higher thermal energy requirements. With American derating, the safe operation is obtained but it creates problems of dissatisfaction on the user with the application since the user does not obtain the final temperatures which satisfy him/her.

As mentioned in the preceding paragraphs, in the prior art there is no solution to the drawbacks in the gas household appliances when operating at high altitudes. For more clarity, the Asian countries are those with the highest density in the manufacturing of continuous flow water heaters that operate with fuel gases, but in its commercial offer, they restrict the operation to countries like Peru and Bolivia because of the large urban settlements that have altitudes greater than 3000 meters above the sea level and in addition they have to make major technical efforts to use their products in other countries of the Andean region, in all cases sacrificing functional performance (end-user satisfaction) in order to not jeopardize the safety.

SUMMARY

The present invention contemplates the design, development and manufacturing of continuous flow water heater which mitigates the effects of altitude ensuring proper operation under different atmospheric conditions present in the Andean region; in addition, the operation at low altitudes is also appropriate.

There are several contributions to the state of the art of the continuous flow water heater which attenuates the altitude effect, especially when it is subjected to different atmospheric conditions, the most representative are:

-   -   1—The application of a combustion system which distributes         pulses for the injection gas, ensuring a high primary air         entrainment, which works to mitigate the decrease in oxygen         obtained with the increasing of the altitude.     -   2—Applying a deflector in the head of the burners, to improve         the crossed ignition of the combustion system when environment         temperatures are low.     -   3—By being a natural draft boiler, it is contemplated from the         design of the assembly of an evacuation duct which ensures         proper evacuation of the fumes and the efficiency of the heat         transfer system.     -   4—Applying a diffuser of defined geometry which increases the         persistence of the fumes to improve heat transfer and to         increase the system efficiency.     -   5—The integration of various security devices to ensure proper         and safe operation of the product.

BRIEF DESCRIPTION

FIG. 1 Isometric view of the combustion system.

FIG. 2 Front view of the combustion system.

FIG. 3 Side view of the combustion system.

FIG. 4 Exploded view of the heater that mitigates the effect of altitude,

DETAILED DESCRIPTION

The continuous flow water heater that attenuates the effect of altitude is composed of four basic elements, which interaction in the operation provide optimum performance in different climatic zones, without affecting product performance and ensuring user safety. The four elements forming part thereof are:

1. A combustion system.

2. A heat transfer system.

3. A mechanical structure.

4. A control system and product safety.

1. Combustion System

The combustion system is composed of four parts: a rectangular bottom base made of injected aluminum (FIG. 1-A, FIG. 2-A) which includes two sections, a lower section (FIG. 1-C, FIG. 2-C) and an upper section (FIG. 1-B and FIG. 4-B). Each section contains 4 channels (FIG. 3-D, FIG. 4-D) which are arranged horizontally, divided in the middle by a channel perpendicular to the previous channel (FIG. 3-E, FIG. 4-E). This will provide six cavities, separated into groups of three by the center channel (FIG. 3-E, FIG. 4-E). These channels allow the flow of gas. The rectangular base has a variable length between 20 and 25 centimeters and a width varying between 8 and 15 centimeters. The lower section (FIG. 1-C) has on its outer perimeters and the perimeters of the channels, one thin interior channel (FIG. 4-F), in which the heat-resistant paste is provided whereby both sections are assembled through a pressure pressing system. The upper section consists of a die-cast aluminum cover (FIG. 1-B and FIG. 4-B) with 50 evenly distributed nozzles, with a diameter of less than one millimeter. In the bottom center of the bottom section, in the central channel (FIG. 3-E, FIG. 4-E) a distributor (FIG. 1-G, FIG. 2-G, FIG. 3-G) is located, which connects the main valve with the injector system. The rectangular base elements comprise a on called unified fuel injection system. The proposed system distributes the impulses and only runs with an assembly operation, improving air drag and decreasing the probability of failure by decreasing assembly operations with high risk of leakage problems.

The lower rectangular base is assembled to four mixers made of stainless steel (FIG. 1-H, FIG. 2-H, FIG. 4-H). Said mixers comprise a set of defined geometry, being comparable to two opposed and overlapping triangles, so that the vertices thereof are in the center (FIG. 1-N) and the bases of said triangles form the ends of the mixers (FIG. 1-P). The set of four mixers having a variable height between 8 and 11 cm, preferably a width varying between 8 and 15 centimeters, and a length varying between 20 and 25 centimeters. From the lower base of each mixer, two rectangular shape flat surfaces extend laterally (FIG. 1-Q, FIG. 2-Q, FIG. 4-Q), which embrace each channel of the rectangular base on both sides, attaching thereto via two tabs, also of rectangular shape (FIG. 1-M, FIG. 2-M, FIG. 3-M). Accordingly, the adequate air entrainment with a ratio area/port neck area superior than conventional systems is ensured. The body of the mixer is made of stainless steel that retains its technical specifications under high operating temperatures without problems of corrosion or structural instability. Mixers are sealed by lateral plates (FIG. 1-I, FIG. 4-I), which allow to maintain the tightness required to ensure that only the gas passes through the perforations in the upper section of the rectangular base and not dispersed.

On top of the two external mixers, extending along its length, there are two stainless steel deflectors so that the combustion system will have a front and a rear deflector (FIG. 1-J, FIG. 2-J, FIG. 3-J, FIG. 4-J). Said deflectors are composed by a flange of 7 mm, with an angle opt approximately 90 degrees, which is broken in its central zone, generating a bottom angle (FIG. 1-K, FIG. 2-K, FIG. 3-K, FIG. 4-K). The presence of deflectors makes easier the cold start, thus preventing the gas to go down to the injectors. The from injector smaller to allow the assembly of the spark plugs.

Indeed, in the front mixer, below the deflector sealed thereto, a support of spark plugs is assembled (FIG. 1-L, FIG. 2-L, FIG. 3-L, FIG. 4-L). Said support is composed by a rectangular shape, which is assembled to the mixer through two lateral flanges and it has along its upper and lower edge, a flange quartered. The cavities which are derived from these sections house the spark plugs (FIG. 4-R), which are secured by an additional part of the support (FIG. 4-S). This spark plug system composes the flame sensor, which, at the time when the flame goes out, turns off the gas supply, increasing thereby the equipment security. The spark plugs are powered by batteries.

The combustion system thus described is secured to the casing of the continuous flow heater which attenuates the effect of altitude by fastening brackets, which lie at the back of the combustion system, at the height of the rear deflector (FIG. 1-O, FIG. 2-O, FIG. 3-O). These mounting brackets, besides attaching the fuel system to the casing, have a shape that fits the side and upper limbs of the four mixers (FIG. 1-T), supporting them, but at the same time ensuring that they are always an equal and calculated distance to each other. Indeed, the mixers are located at the same distance from each other to allow uniform combustion.

2. Heat Transfer System

The heat transfer system essentially comprises three main parts: a rectangular and hollow inside heat exchanger, (FIG. 4-U), a diffuser (FIG. 4-V) and smoke evacuation duct (FIG. 4-W). Around the exchanger body a serpentine is disposed which contains water (FIG. 4-X). The heat exchanger has dimensions which ensure proper assembly with the diffuser, causing a seal to prevent leakage of heat to the environment. The diffuser retains warm air flow to improve heat transfer to the water, prevents the income of external air flow that may affect the combustion system and distributes the evacuation of hot gases into the air exhaust duct in which these hot gases are channeled to the outside of the installation site, improving the quality of the air inside the enclosure and the overall safety.

3. Mechanical Structure

It consists of two parts, front casing (FIG. 4-Y) and back casing (FIG. 4-Z). The back casing is the support for all parts of the heater, on top of it the vast majority of components are assembled and it is subsequently secured in the location of final use. It has several mechanical pressed to improve its structural rigidity and its contour delimits the assembly area to the product structure. The casing is a single piece with several manufacturing processes (cutting, punching, stamping, painting) covering the structural and functional systems of the product.

4. Control System and Product Safety

It is composed by a variety of temperature and flame sensors which eliminate the possibility of product unsafe operation. The heater turns off the flow of gas to the main burner if any of the following situations occur.

-   -   1. If an obstruction is generated in the hot gases exit in the         exhaust duct.     -   2. If there are counterflow air currents that prevent the normal         evacuation of the fumes.     -   3. If the water temperature increases to levels which affect the         heat exchanger (approximately 85° C.).     -   4. If an adequate ignition is not generated.     -   5. If the water pressure at levels higher than those specified         in the product specifications.

They are many situations that could generate gas cutting, however the most common are described herein. 

1. Continuous flow water heater that attenuates the effect of altitude, characterized by: A combustion system. A heat transfer system. A mechanical structure. A control system and product safety.
 2. Continuous flow water heater that attenuates the effect of altitude, characterized by, according to claim 1, a combustion system, consisting of four pieces: A unified injection system made of injected aluminum Four stainless steel mixers Two deflectors A support for spark plugs
 3. Continuous flow water heater that attenuates the effect of altitude, characterized by, according to claim 2, a combustion system comprising a unified injection system, comprising a rectangular bottom part made of injected aluminum comprising two parts (a lower section and an upper section) joined by pressure, carrying a stick around the bottom piece.
 4. Continuous flow water heater that attenuates the effect of altitude characterized by, according to claim 2, an injection system comprising a rectangular base with a variable length between 20 and 25 centimeters and a width varying between 8 and 15 centimeters.
 5. Continuous flow water heater that attenuates the effect of altitude, characterized by, according to claim 2, a unified injection system composed by a rectangular base made of injected aluminum, composed by two pieces, held together by pressure, carrying a stick around the bottom piece: A rectangular-shaped lower section made of injected aluminum, which contains four channels which are arranged horizontally, divided in the middle by a channel perpendicular to the previous channel, thereby generating six cavities. A rectangular-shaped upper section made of die-cast aluminum, which contains four channels which are arranged horizontally divided in the middle by a channel perpendicular to the previous channel, thereby generating six cavities.
 6. Continuous flow water heater that attenuates the effect of altitude characterized by, according to claim 5, a lower section which has an interior and a very thin channel in the external perimeter and channel perimeters to accommodate the sealing adhesive of the two parts of the injection system.
 7. Continuous flow water heater that attenuates the effect of altitude characterized by, according to claim 5, having a distributor in the lower section and center channel of the bottom center of the unified injection system.
 8. Continuous flow water heater that attenuates the effect of altitude characterized by, according to claim 5, having 50 nozzles evenly distributed, with a diameter less than a millimeter in the channels of the upper section of the unified injection system.
 9. Continuous flow water heater that attenuates the effect of altitude characterized by, according to claim 1, a heat transfer system, comprising four mixers made of stainless steel, which form a set of defined geometry, this being comparable to two opposing and overlapping triangles, so that the vertices are at the center and the bases form the ends of the mixers. The mixers are tightly sealed by the lateral sides with stainless steel blades that replicate the form of the burners.
 10. Continuous flow water heater that attenuates the effect of altitude characterized by, according to claim 9, a set of four mixers having a variable height between 8 and 11 centimeters and a width varying between 8 and 15 centimeters and a length varying between 20 and 25 centimeters.
 11. Continuous flow water heater that attenuates the effect of altitude characterized by, according to claim 9, four mixers, from which the lower base of each of them, two rectangular shape flat surfaces extend laterally which are bent at its tip generating a tab, also rectangular shape, for being fixed on the unified injection system.
 12. Continuous flow water heater that attenuates the effect of altitude characterized by, according to claim 9, four mixers sealed on the sides by stainless steel caps.
 13. Continuous flow water heater that attenuates the effect of altitude characterized by, according to claim 1, two stainless steel deflectors, which are made by a flange of 7 mm, with an angle of approximately 90 degrees, which is broken in its central zone, generating a low angle. One is a rear deflector and the other one is a front deflector, which has a shorter flange.
 14. Continuous flow water heater that attenuates the effect of altitude characterized by, according to claim 1, a support of rectangular spark plugs, which are assembled on top of the front mixer, by two side flanges and having along its top and bottom edges a flange quartered, generating four chambers which house the spark plugs, fastened by a support supplementary piece.
 15. Continuous flow water heater that attenuates the effect of altitude characterized by, according to claim 9, four mixers connected at their lower end and supported to the mechanical structure by a cradle.
 16. Continuous flow water heater that attenuates the effect of altitude characterized by, according to claim 1, a heat transfer system comprising: A heat exchanger A diffuser A smoke evacuation duct.
 17. Continuous flow water heater that attenuates the effect of altitude characterized by, according to claim 1, a mechanical structure composed by two die-cut and painted parts: a front rectangular shape casing with volume and that at its rear has a crescent-shaped cavity to allow pipeline to pass over the evacuation duct and a back casing, the latter being the support for all parts of the heater, with receiving parts for most components and serving as the basis for the final fastening of the heater. 